Package with individual pockets for pads



E. A. ZACKHEIM 3,162,306

PACKAGE WITH INDIVIDUAL POCKETS FOR PADS Filed May 9, 1965 4 Sheet s lVENTOR. w 52/ ,4 ZAcK/rE/M 34 ATTORNEY Dec. 22, 1964 E. A. ZACKHEIM3,162,306

PACKAGE WITH INDIVIDUAL POCKETS FOR PADS Filed May 9, 1963 4Sheets-Sheet 2 II I. p. Ir.

5'4 3W 3/ 44 0 INVENTOR.

54/ 4. ZAzKzYf/M 4 J4} 11:115. BY

44/ a 3/ M V ATTORNEY D c. 2, 1 E. A. ZACKHEIM PACKAGE WITH INDIVIDUALPOCKETS FOR PADS 4 Sheets-Sheet 5 Filed May 9, 1963 INVENTOR. 54/ AZ4c-Kfl5/M W4 W ATTORNEY Dec. 22, 1964 E. A. ZACKHEIM PACKAGE WITHINDIVIDUAL POCKET-S FOR PADS Filed May 9, 1963 4 Sheets-Sheet 4 IN VENTOR. 54/ ,4. .ZiC/(AE/M ATTORNEY United States Patent 3,162,366 PACKAGEWETH INDEVIDUAL PGCKETS FUR PADS Eli A. Zackheim, Princeton, N.J.,assignor to Johnson & .lohnson, a corporation of New Jersey Fiierl May9, 19%, Ser. No. 279,057 Claims. (Cl. 2%-53.2)

The present invention relates to medicated pads for application to theskin, more particularly to such pads which are in the form of relativelysmall pieces most suitably stamped or cut from a layer of sheetmaterial, and to a novel package therefor and a method of manufacturingthis package.

According to this invention, a plurality of pads are assembled withother sheet material to form a single laminated package in which thepads may be enclosed in sterile condition in individual pockets. Theindividual pads remain in place in the product sheet from which they arestamped or cut and this product sheet becomes part of the packagelaminate. The laminate comprises a relatively heavy backing sheet, acover sheet, and the product sheet; and the sheets are assembled withthe product sheet sandwiched between the backing sheet and the coversheet. The product sheet is adhered to the backing sheet, on one side,and the cover sheet, on the other side, in areas completely surroundingthe pads to form a plurality of scaled individual pockets enclosing thepads. The backing sheet at each of the pockets is scored or grooved fromthe outside of, and partially through, the backing sheet along abreaking line crossing the pocket, and the laminate is cut from thebreaking line to the nearest edge of the laminate on each side of eachpocket; thereby forming a tab adapted to be separated or detached easilyfrom the package by tearing the backing sheet and the cover sheet alongthe breaking line. Separation of one of the tabs from the package opensone of the pockets and exposes the pad it contains without disturbingthe integrity of the remainder of the package.

In a preferred embodiment of this invention, the individual pads areimpregnated with a hemostatic agent and the pads are intended for useduring shaving to stop the flow of blood and help heal any cuts whichmay occur. In this case, it is important that a pad be immediatelyavailable when needed but that the remainder of the pads in the packagebe maintained free of contamination from blood, soap, and other foreignmaterials. It is an important feature of the package of this inventionthat each of the tabs may be detached easily to expose a hemostatic padwhen needed. As will be explained more fully hereinafter, the tab may bedetached in such a way that the pad remains in the tab with its endprotruding therefrom, or the pad may be left protruding from thatportion of the pocket which remains with the package after the tab isdetached. While there are certain advantages to either of thesetechniques, in either case, the pad, itself, is readily available foruse.

Another important advantage of the package of this invention is that itis adapted to "be sterilized quickly in a carboxide autoclave. Thevarious parts are designed to be assembled in such a way thatsterilizing gases may penetrate readily into the individual pockets ofthe completed package and thereby completely sterilize its contents.

It also is preferred that the cover sheet be transparent so that thepads are visible in the pockets from one side of the package. Forinstance a colored hemostatic agent may be applied to the visible padface so as to bring them sharply into view and make them clearly visibleto the consumer.

The method of this invention, wherein the individual 3,162,366 PatentedDec. 22, 1964 pads remain in place in the product sheet from which theyare cut and the product sheet becomes part of the package laminate, alsois highly advantageous because it facilitates the definite positioningof the pads in the package in accordance with the arrangement in whichthey are cut from the product sheet and also facilitates the formationof the sealed pockets enclosing the pads.

The pads are either cut from the product sheet after it is applied tothe backing sheet, in which case they may be completely cut; or they areat least partially cut from the product sheet prior to the applicationof the product sheet containing the pads to the backing sheet. Normally,in the latter case, the pads are almost completely cut from the productsheet except for short nibs on opposite sides of the pads which hold thepads in position. The nibs also may be used when the pads are cut afterapplication of the product sheet to the backing sheet for convenience inretaining the pads in position and to insure sterility as will beexplained more fully hereinafter.

Other and further advantages of this invention will be apparent from thefollowing description and claims taken together with the drawingswherein:

FIG. 1 is a view in perspective of a backing sheet of a package inaccordance with one embodiment of this invention;

FIG. 2 is a view of the same backing sheet after it has been coated witha plastic film;

FIG. 3 is a view in perspective of a product sheet according to thisinvention superimposed over the backing sheet of FIG. 2;

FIG. 4 is a partially broken away view of portions of the sheets of FIG.3 after the product sheet has been adhered to the backing sheet;

FIG. 5 is an enlarged sectional view line 55 of FIG. 4;

'FIG. 6 is a view in perspective of a smaller fragment of the sheets ofFIG. 4 after the pads have been cut from the product sheet;

FIG. 7 is an enlarged view partly in section and partly in elevationtaken along the lines 7-7 of FIG. 6;

FIG. 8 is an enlarged sectional view along the line 8-8 of FIG. 6;

FIG. 9 is a view in perspective of the assembled sheets off FIGS. 3 and4 with a cover sheet positioned above t em;

FIG. 10 is a view of a fragment of the sheets of FIG. 9 after the coversheet has been adhered to the product sheet in areas surrounding thepads to form a laminate comprising pockets for the pads;

FIG. 11 is a view in perspective of the sheets of FIG. 10 with thelaminate inverted, showing the scoring and die cutting of the laminate;

FIG. 12 is a view in perspective of a fragment of the laminate of FIG.11 in an upright or noninverted, position;

FIG. 13 is an enlarged sectional view along the line 1313 of FIG. 12;

FIG. 14 is an inverted enlarged sectional view taken along the line 1414of FIG. 11;

FIG. 15 is an enlarged sectional view taken along the line 15-15 of FIG.12;

FIG. 16 is a view in perspective showing one of the tabs being removedfrom the package laminate;

FIG. 17 is a fragmentary view in perspective which also shows removal ofa tab from the package of this invention;

FIG. 18 is a smaller fragmentary view in perspective showing the tabbeing removed with the pad in place in the tab;

FIG. 19 is another in the tab;

taken along the perspective view of the pad in place wherein the pad isretained in the package after the tab is removed;

FIG. 21 is a fragmentary view in perspective showing a portion of abacking sheet according to a slightly different embodiment of thisinvention wherein a laminating adhesive is applied in a pattern definingthe pockets;

FIG. 22 is a view in perspective showing a product sheet wherein thepads have been partially cut from the sheet and together with the sheetare positioned above the backing sheet of FIG. 21; 7

FIG. 23 is a fragmentary view in perspective showing the sealing of theproduct sheet to the backing sheet;

FIG. 24 is a-fragmentary View in perspective showing the positioning ofthe cover sheet over the laminated sheets of FIG. 23; V

FIG. 25 is another fragmentary View in perspective showing the sheets ofFIG. 24 after they have been ad'- hered to one another to formfpocketssurrounding the pads;

nate'inverted for the purpose of illustrating the cutting and scoringthereof; a

FIG. 27 is an enlarged sectional view similar to FIG. 13 buttakenthrough the embodiment of FIGS. 21-28; FIG. 28 is an enlarged sectionalview similar to FIG. 14, but also of the embodiment of FIGS. 21-28. 7Referring particularly to FIGS. 1-15 of the drawings,

7 there is shown a package according to a preferred embodiment of theinvention and a method of manufacturing it.

Pro. 26 is a view similar to FIG.11 showing the lamiposition.

4. the product sheet, but leaves a pair of short nibs 38, along thecenter line AB in FIG. 6, for retaining the pads in It should be notedthat the shape of the pads 37, as cut, is the same as the patterninwhich the medication 35 or hemostatic agent originally was applied tothe product sheet. The application pattern for the'medica tion need notbe the same as the shape of the pads although it must apply sufficientmedication to the pads in the right locations, v

FIG. 7'is a sectional view taken along one edge of one of the pads 37'and illustrates one of the nibs 33 referred to above. 'These nibs 38 arelocated along the line A-B which represents one of the lines along which7 the backing sheet will be scored to provide a breaking line forremoval of tabs from the package, as will be described more fullyhereinafter.

Both FIGS. 7 and 8 also show that when the pads.37

' are cut from the product sheet 34, the dies also cut through thelaminating film 33 and penetrate the backing sheet 31 slightly. Thus,cuts 30 are formed in the laminating film 33 in the outline of the pads37. These cuts 30' are for the purpose of facilitating sterilization ofthe interior of the package through the backing sheet 31. When ethyleneoXide or steam is used for sterilization in an ordinary productionsterilization cycle of one-half to one hour, the thermoplasticlaminating film 33 might provide a barrier to penetration of thesterilizing gas through the backing sheet if it were not for theabovereferred-to cuts.

FIG. 9 shows a cover sheet 41, which preferably 18 transparent, inposition over lthe'product sheet 34, and

FIG. 1 illustrates a backing sheet 31 which is'relatively ,7 heavycompared with the cover for the package and" normally considerablyheavier than the productsheet from which the pads are cut. Typically,; adie-cut bleached sulfate paper board about 0015-0020 inch thick may beused for this purpose. A small hole 32 is punched adjacent one of theedges of the sheet for Vhanging the package on a rod for storage ordisplay purposes.-

In F1622, a thin laminating film 33 of a thermoplastic material such assaran, polypropylene, or linear polyethylene, is applied to the topsurface of the backing 'sheet 31 in the "area where product sheet are tocontact one another. may be only a fraction of a mil'in thickness but issubstantially continuous as applied r to the backing sheet. 'FIG. 3illustrates a product sheet 34 in position above the coated portion ofthe backing sheet 31. The outlines of the pads to be cut from theproduct sheet are already defined by medication 35 applied to theproduct sheet in the shape of the pads. The product sheetv34 is formedfrom material which is absorbent enough to contain the blood or anyother fluid for which it is intended, and yet firm, or stiff, enough togive' medication 35 and absorb the individual pads sufficientrigidity,or body, for use. When the pads are intended for hemostatic purposes inconnection with shaving, as described briefly hereinbee fore, theproduct sheet may be cut from a Whatman #3 filter paper in theneighborhood of 0.0100.015'inch thick. This" filter paper is relativelyporous as compared with the backing sheet. .The hemostatic agent maybeapplied 7 to the top surface of the product sheet in the outline of thebackingsheet and the This film 33 FIG. 10 illustratesa portion of thepackage after the cover sheet 41 has been adhered to the product sheetin the sealingarea 36-surroundin'g the pads to form the packagelaminate. Preferably, the cover sheet 36 is a material which may bevheat sealed to the product sheet 34. For instance, a linearpolyethylenefilm about one mil or less'in thickness may be used for this purpose, ora laminate of glassine and vinylite may be employed.

In the latter case, the vinylite, besides being heat scalable, should.also be heat ste'rilizable, i.e., capable of retaining, its integrityand its seal, at temperatures in the neighborhood of 250 F. A glassinevinylite laminate wherein. about 25 pounds perream of glassine and 5-10:pounds per'ream of vi'nylite are employed, is suitable for. thispurposel, lt should be noted that the cover sheet may be sealed to theproduct sheet in the same pattern as the product sheet is sealed to thebacking sheet.

- However, while this is. convenient, it is not necessary.

When the cover sheet 41 is sealed to the product sheet :34, pockets 42enclosing the pads 37 are completed. Sufficient clearancezis allowedbetween the edges of the pockets 42 and the pads 37 to allow the pads tobe removed readily therefrom when desired.

The laminated package according to'this embodiment is completed, asshownin FIGJ 11, byinverting the sheets of FIG. 10 and die cutting andscoring the laminate the pads by silk screening, gravure printing,impregnation V or the like. y

FIGS. 4 and 5 illustrate the heat sealing of the product sheet to thebacking sheet. 'A heat sealing die, or shoe,

is used to apply heat to the laminate of the product sheet. and thebacking sheet in a pattern which establishes a I heat sealing area 36surrounding the. individual pads. Thus, the product sheet is waled tothe back sheet only in the areas surrounding the pads to be c'ut'fromthe product sheet.

FIG. 6 illustrates the laminate of FIG. 4 after pads 37 have been cutfrom the product sheet 34. A die is used for this purpose which almostcompletely cuts the pads from to form a tab 43 for each of the pads 37and its corresponding pocket 42; The backing sheet 31 is scored from itsbottom surface, part way through its thickness .to form two breakinglines or grooves 44. Each of the breaking grooves 44 runs. through a rowof the pads 37 and their corresponding pockets 42 in such a way as tocross the pockets at the point where it is desired to open them. Thelaminate is cut from each of the breaking grooves 44 to the nearest edgeof the laminate on each "side of each of the pockets 42 to form tabs 43which are individually separable fromv the remainder of the package bybreaking the backing sheet' and the cover sheet along the appropriatebreaking groove 44. Thecorners 45 of the tabsv 43 are beveled at theends of the tabs during" the die cutting, asshown most clearly in FIGS.ll'and ,12 for conveniencein'gripping and removing the tabs 43.

FIGS; 12- 5 illustrate portions "or the completed laminated'packageaccording to this embodiment of the invention. It will be seen that themedicated pads 37 remain in position in the product sheet 34 and areenclosed in sealed pockets 42 formed by the backing sheet 31, theproduct sheet 34, and the cover sheet 41. These pockets 42, whensterilized, remain sterile and protect the pads 37 from airbornebacteria and other contamination. However, the package is so designedthat the pockets 42 are penetrable by sterilizing gases under pressure.The penetration of sterilizing gases into the pockets through thebacking sheet 31 and the cuts 30 in the thermoplastic film 33 applied tothe sheet has been described hereinbefore. As mentioned previously, thenibs 38, shown most clearly in FIGS. 6 and 7, have an importantsecondary function of assuring the sterility of the pockets 42. A quickglance at FIG. 14 will show that the breaking grooves 44 in the backingsheet might contact the cuts 30 made in the backing sheet 31 through thelaminating film 33 in the outline of the pads where the grooves 44 wouldcross these cuts, if it were not for the nibs 38. Thus, one of thegrooves 44 is shown dotted in FIG. 7 and crossing under the pads 37through the nibs 38 so as to avoid the possibility of joining the cuts30.

FIGS. 16-20 illustrate two ways in which the laminated package of thisinvention may be used. As mentioned hereinbefore, the individual tabs 43may be detached from the package in such a way that the pad 37 remainsin the tab 43 and is removed from the package with the tab as the tab isdetached by tearing the package along the breaking groove 44. In thiscase, the pad 37 is held in the tab 43 by the fingers gripping the tab,as shown in FIG. 16, and the other end of the pad 37 protrudes from thetab 43 after it has been removed from the package, as shown in FIGS. 18and 19. The tab 43 then may be used as a holder for applying the pad 37to a cut or the like.

On the other hand, it may be desirable to leave the pad 37 in positionin the package after the tab is removed therefrom, as shown in FIG. 20.To accomplish this, the hand gripping the package also is applied to oneend of the pad 37 and the tab 43 is gripped by the other hand in such away as not to contact the opposite end of the pad. One advantage of thistechnique may be that it leaves the exposed pad 37 free to be removedeasily from the package and applied directly to a cut. In both of theabove-described cases the tab 43 may be removed easily from the packageby tearing along the breaking groove or line 44 without disturbing theintegrity of the remainder of the package, or in the case of a sterilepackage, without interfering with the sterility of the remainder of thepackage.

FIGS. 2128 illustrate a package according to a somewhat difierentembodiment of the invention and a method of manufacturing this package.The materials used are the same as, or similar to, those described inconnection with FIGS. l-l5, unless otherwise stated. FIG. 21 illustratesthe application of a laminating adhesive 51 to the backing sheet 31 in apattern. This pattern corresponds to the pattern in which it is intendedto seal the product sheet to the backing sheet. FIG. 22 shows a productsheet 52 superimposed above the adhesive area of the backing sheet. Aplurality of pads 53 are already cut from the product sheet but areretained in position therein by a pair of short nibs 54 connecting eachof the pads 53 with the sheet 52. These nibs 54 are easily broken whenit is desired to remove the pads from the package. FIG. 23 illustratesthe positioning of the product sheet 52 containing the pads 53 on thebacking sheet with the pads located within the adhesive-free areas ofthe backing sheet. The backing sheet 31 is adhered to the product sheet52 through the laminating adhesive 51 by the application of heat and/ orpressure to the two sheets. FIGS. 24 and 25 illustrate the applicationof a transparent cover sheet 55 over the product sheet to completepockets 56 enclosing the pads, Again, the cover sheet 55 may be sealedto the backing sheet 31 by applying heat and pressure through the coversheet 55 in areas surrounding the 6 pads 53 but spac'ed therefromsufiiciently to define clear ance between the edges of the pads and theedges of the pockets. FIG. 26 is similar to FIG. 11 and also illustrates the way in which the laminated sheets are die cut and scored toform tabs 57 by inverting the laminate and cutting through the bottom ofthe backing sheet.

As mentioned hereinbefore, FIGS. 27 and 28 are similar to FIGS. 13 and14, and illustrate this embodiment of the invention in the same way asFIGS. 13 and 14 illustrate the embodiment of FIGS. 1l5. As shown inFIGS, 27 and 28, in this embodiment of the invention, there is nolaminating film under the pads 53. Thus, sterilizing gases may passdirectly through the backing sheet 31 into the pockets 56 enclosing thepads 53 and it is not necessary to cut into the backing sheet in theoutline of the pads, as in the embodiment of FIGS. 1-15. This allows thepads to be cut from the product sheet prior to assembly of the productsheet with the backing sheet, as described above.

As described in connection with FIGS. 1-15, the pads 53 are enclosed inindividual pockets 56 formed by the backing sheet 31, the product sheet52, and the cover sheet 55, and may be removed easily from these pocketsby either of the techniques described in connection with FIGS. 16-20,merely by tearing one of the tabs 57 from the remainder of the package.Again, removal of one of the tabs, only opens one of the pockets andprovides access to one of the pads, and does not disturb the integrityor the sterility of the remainder of the package.

A still different preferred embodiment of this invention is in thenature of an improvement over and a combination of certain of thefeatures of each of the foregoing embodiments. Referring particularly toFIGS. 1- 15, after the heat sealable laminating film 33 is applied tothe backing sheet 31, sterilizing cuts, not shown, are made through thefilm 33 approximately where each of the pads 37 will cover the film insuch a way that the cuts enter each of the pockets 42. The sterilizingcuts are carefully located so that they will not strike the breakinggrooves 44 in the bottom of the backing sheet 31 and therefore allowairborne bacteria and other contamination to pass into the pocketsthrough the breaking grooves 44 and the sterilizing cuts. Neverthelessthe cuts do allow penetration of sterilizing gases under pressure intothe pockets 42 through the backing sheet 31 and then through thesterilizing cuts, themselves. Next'the product sheet 34, which in thisembodiment is like the product sheet 52 because the pads are alreadypartially cut from the product sheet, is placed in position over theheat sealable film 33 and the cover sheet 41 is positioned over theproduct sheet. When the sheets are in position all three sheets aresealed together to form a laminate with the product sheet 34 between thebacking sheet 31 and the cover sheet 41. A heat sealing die or shoe isused which applies heat and pressure to the laminate in the sealingpattern shown in FIG. 4 to seal one face of the product sheet 34 to thebacking sheet 31 and the other face of the product sheet to the coversheet 41 in areas completely surrounding said pads without adhering thepads to backing sheet or the cover sheet. The product and the method ofthis embodiment are in every other respect the same as those of FIGS.1-15. The chief advantage of this embodiment is in its simplicity andthe elimination of the need for precise registration as between the nibs38 and the grooves 44, or the need for applying the laminating adhesiveor film to the backing sheet in a careful pattern as described inconnection with the embodiment of FIGS. 21-28.

Having now described the invention in specific detail and exemplifiedthe manner in which it may be carried into practice, it will be readilyapparent to those skilled in the art that innumerable variations,applications, modifications, and extensions of the basic principlesinvolved may be made without departing from its spirit or scope.

The invention claimed is:

1. A package with individual pockets for pads of sheet 7 materialcomprising a product sheet portion and coextensive portions of arelatively heavy backing sheet and a cover sheet, said product sheetportion being sandwiched between the coextensive portions of the backingsheet and the cover sheet to form a laminate, said product sheet portioncomprising a plurality'of pads at least partially cut from the productsheet portion and'remaining in position therein, said product sheetportion in an area completely surrounding said pads being adhered oneside to the backing sheet and the other side to the cover sheet,

but loose from said backing sheet and said cover sheet throughout theareas of said pads to form a plurality of scaled pockets enclosing saidpads, said backing sheet at V the individual pockets being scored fromthe outside of and partially through the'backing sheet along a breakingproduct sheet except for short nibs connecting the pads with the sheet,

' 3. A package for pads of sheefmaterial according to claim-1, whereinmedication is applied-r te at least one surface oflth'e pads and theinteriors of the pockets are sterilized to "provide a sterile sealedpackage. 4. {A package for pads .of sheet material according to claim 1,wherein the pads are :formed of absorbent and :firni sheet materialandla heniostatic agent -is.applied .to at least one surface of thepads.

5. A package for pads of sheet claim 1, wherein the coversheetiistransparent and forms the top of the pockets and .the pads are visiblethrough the cover sheet when imposition in the pockets.

References Cited iin'ithe file of this patent V I UNI TED STATES PATENTSI 1,310,729 Appelbee July 22, 19 19 1,492,101 Mordecai Apr. 29, 1924.2,061,1391 Cohen ..a Novylj, 1936 2,616,559 Hyland Nov. .4, 19523,063,555 Hanington Nov. 13, 1962 FOREIGN PATENTS 1,104,9 60 France*Jnne 22, 1955 material according to

1. A PACKAGE WITH INDIVIDUAL POCKETS FOR PADS OF SHEET MATERIALCOMPRISING A PRODUCT SHEET PORTION AND COEXTENSIVE PORTIONS OF ARELATIVELY HEAVY BACKING SHEET AND A COVER SHEET, SAID PRODUCT SHEETPORTION BEING SANDWICHED BETWEEN THE COEXTENSIVE PORTIONS OF THE BACKINGSHEET AND THE COVER SHEET TO FORM A LAMINATE, SAID PRODUCT SHEET PORTIONCOMPRISING A PLURALITY OF PADS AT LEAST PARTIALLY CUT FROM THE PRODUCTSHEET PORTION AND REMAINING IN POSITION THEREIN, SAID PRODUCT SHEETPORTION IN AN AREA COMPLETELY SURROUNDING SAID PADS BEING ADHERED ONESIDE TO THE BACKING SHEET AND THE OTHER SIDE TO THE COVER SHEET, BUTLOOSE FROM SAID BACKING SHEET AND SAID COVER SHEET THROUGHOUT THE AREASOF SAID PADS TO FORM A PLURALITY OF